Switchgear & Circuit Breaker Specification … & Circuit Breaker Specification Developments For ... Ship spec/purchase spec required Commercial-Off-The-Shelf ... for Electrical Systems

NSWCPD 429, Advanced Electrical Power Systems Branch

9 December 2015 - NSRP ETP MEETING 1 OF 17DISTRIBUTION STATEMENT A: Approved for public release: distribution unlimited..

Switchgear & Circuit Breaker

Specification Developments

For

U.S. Navy Ships

Pete Tahopoulos/George Rasich

Naval Surface Warfare Center Philadelphia Division (NSWCPD)

Code 429

NSRP ETP MEETING



˃ Background

* DDG 91AF

Ship spec/purchase spec required Commercial-Off-The-Shelf (COTS) circuit

breakers to meet IEC/UL 489 Supplement SB component specs

COTS circuit breakers were also qualified as subcomponents as part of

switchboard/load center First Article testing

In addition, NSWCCD-SSES (now NSWCPD) was tasked by PMS 400 to conduct

Risk Reduction testing on several Cutler-Hammer (now Eaton) COTS circuit

breakers from 2000-2002

Included mil-spec QPL type testing for endurance, interruption, and

temperature rise

This testing has not been performed again since 2002

* LCS and DDG 1000

Programs invoked Naval Vessel Rules (NVR) requirements for COTS circuit

breakers

NVR requirements not very clear

Risk Reduction testing not performed for these programs

NAVY COTS CIRCUIT BREAKER SPECS



˃ Background (continued)

* Circuit Protection Integrated Product Team (CPIPT)/Circuit Protection

Technical Advisory Board (CPTAB)

CPIPT was chartered by NAVSEA in 2006 to address circuit protection

issues across the fleet

CPIPT transitioned to the CPTAB in 2013

Membership includes NSWCPD, SEA 05Z, SEA 08K, BPMI, Puget Sound

Naval Shipyard, SUBMEPP, Electric Boat, HII-Ingalls, and HII-Newport News

NAVSEA directed the CPTAB to develop COTS circuit breaker specs for

Navy applications to standardize requirements




˃ UL 489D

* For low voltage molded case type circuit breakers

* Published in April 2012

˃ UL 1066A

* For low voltage power type circuit breakers

* Published in April 2013

˃ UL 2831

* For medium voltage vacuum type circuit breakers

* Published in May 2013

˃ DoD Adoption Notices for each spec were published in October 2014

˃ Specs invoke more stringent requirements than IEC or UL specs in some

areas to be more in-line with Mil-Spec type testing (see Figure 1 on Slide 6 for

an example)

˃ Goal is to demonstrate compliance of existing COTS designs without major

design changes

˃ Specs include electrical ratings (frame sizes, voltage, interruption, and etc.) but do not

address dimensions/size of circuit breakers; for a given frame rating, one OEMs design

may not be a form-fit replacement for another OEMs design




˃ Each spec includes requirements for requalification testing at periodic

intervals (see Figure 2 on Slide 7 for an example)

˃ UL will oversee all testing and maintain an “Online Certifications Directory”

for each specification that lists qualified products similar to the QPL for Mil-Spec

circuit breakers

˃ UL and NAVSEA have an agreement that specs will not be changed without

approval from NAVSEA 05Z Tech Warrant Holder (TWH) for Electrical Systems

˃ Revisions are planned for 2016 based on lessons-learned since publication

including clarification of endurance and silver plating requirements and following

name conventions (“XXXX” will denote frame rating):

* UL 489D: MCCB-XXXX

* UL 1066A: PWRCB-XXXX

* UL 2831: NCVCB-XKV-XXXX

˃ NAVSEA will issue a clarification letter for any program that invokes the specs

before the official revisions have been published





Figure 1 – Excerpt from UL 489D




Figure 2 – Excerpt from UL 489D

Table 7.1

Requalification test programs

Test program RQ1 (5-year intervals)

Test program RQ2 (7-year

intervals)

Test program RQ3 (9-year intervals)

Voltage spike (circuit breakers with electronic devices only)

High available fault current test sequence

Vibration

Circuit breaker endurance load operations ("with current") and selected accessory temperature rise

Temperature rise @ 50°C ambient

Electromagnetic interference (circuit breakers with electronic devices only)

Verification of accessories Verification of accessories

Circuit breaker and selected accessory temperature rise @ 50°C ambient

Shock Fragility

Calibration @ 50°C ambient

Dielectric voltage withstand



˃ Nameplate info

* Standard nameplates for DDG 91AF COTS circuit breakers currently include

the following info (also see Photos 1 and 2 on Slides 9 and 10, respectively)

IEC interruption ratings at different voltages

UL/NEMA interruption ratings at different voltages (if dual-rated)

Frame rating

De-rating has to be taken into account for Navy applications

For example, L-frame rated for 600 amps commercially is used in 400

amp shore power application on DDG 91AF

* Designs qualified to Navy COTS circuit breaker specs will have a different

nameplate that includes the following info

One interruption rating at one voltage rating (480VAC for low voltage

molded case and power circuit breakers)

Frame rating

NO derating has to be taken into account for Navy applications

For example, a circuit breaker qualified at 400 amps to UL 489D can be

used in 400 amp shore power application on DDG 91AF





Photo 1 – Cutler-Hammer COTS F-Frame circuit breaker

IEC ratings

UL/NEMA

ratings







˃ Current/Future Status

* Based on publication of Adoption Notices, SEA 05Z expects that all future

programs using COTS circuit breakers will invoke these specs as

applicable

* Naval Combatant Design Specification (NCDS) (replacement for NVR) will be

updated to reference the new specs

* CPTAB has met with Eaton to discuss testing DDG 91AF COTS circuit

breakers in accordance with the new specs

Eaton likely to start with molded case frame sizes (L-frame, F-frames)

Based on prior Risk Reduction test results and performance of DDG 91AF

circuit breakers to date, NSWCPD believes that Eaton designs should pass

the new Navy COTS circuit breaker spec testing



˃ Background

* DDG 91AF

MIL-S-16036 used as baseline and then tailored through the particular

ship spec / purchase specs

In addition to OEM First Article testing, Risk Reduction testing was conducted

by NSWCCD-SSES (now NSWCPD) on switchboards/load centers

* LCS and DDG 1000

Programs invoked Naval Vessel Rules (NVR) requirements

NVR requirements not very clear

Risk Reduction testing not performed for these programs

* NAVSEA directed the CPTAB to develop mil-specs for Low and Medium Voltage

shock-mounted COTS switchboards to standardize requirements

MIL-SPECS FOR SHOCK MOUNTED (COTS) SWBDS



˃ MIL-DTL-XX653

* Applies to Low Voltage shock-mounted COTS switchboards

* Government/Industry Review (GIR) comments currently being adjudicated

* ECD for publication is January 2016

* Selected features of spec

Requires use of UL 489D molded case circuit breakers and UL 1066A

power circuit breakers

Allows the use of selected COTS components other than circuit

breakers

Allows use of jam nuts

Prohibits use of lock washers except as an integral part of a component

such as a terminal board

Requires incremental torque method for locking devices and a torque

sequence for multiple bolt connections

Allows use of selected NEMA HP5 and HP6 control wire or equivalents

Allows use of alternate methods of construction that differ from the

traditional welded frame

Cybersecurity requirements will be included.




˃ MIL-DTL-XXXXX (TBD)

* Will apply to Medium Voltage shock-mounted COTS switchboards

* NSWCPD submitted a funding proposal to NAVSEA to develop and publish

this spec in FY16

* Will require use of UL 2831 Vacuum Circuit Breakers and have many of the

same MIL-DTL-XX653 features shown on Slide 13




OTHER MIL-SPECS FOR MEDIUM VOLTAGE SWGR

˃ Background

* HII-Newport News developed a spec for CVN 78 hard-mounted Medium

Voltage switchgear since Mil-Specs did not exist at that time

* NAVSEA directed the CPTAB to develop specifications for hard-mounted

Vacuum Circuit Breakers, protective relays, and Medium Voltage

switchboards to standardize requirements

˃ MIL-DTL-32485

* Applies to hard-mounted Vacuum Circuit Breakers

* Published in November 2013

* Includes initial QPL and requalification test requirements

* Designs developed by SPD and DRS for possible current new ship programs

which are the first to be tested in accordance with initial QPL requirements

* SEA 05Z issued an August 2014 letter clarifying silver plating, endurance,

and other requirements



OTHER MIL-SPECS FOR MEDIUM VOLTAGE SWGR

˃ MIL-PRF-32484

* Applies to hard-mounted and shock-mounted Protective Relays used with

vacuum breakers

* Published in November 2013

* Expected to be invoked by current new ship programs

* Includes initial QPL and requalification test requirements

˃ MIL-DTL-32483 and MIL-DTL-32483A

* Applies to Medium Voltage hard-mounted Switchboards

* MIL-DTL-32483 published in November 2013

* Government/Industry Review (GIR) comments for Rev A currently being

adjudicated

* ECD for Rev A publication is January 2016

* Expected to be invoked by current new ship programs

* Requires use of UL 2831 vacuum circuit breakers, MIL-PRF-32484

protective relays, and will have many of the same MIL-DTL-XX653 features

shown on Slide 13



SUMMARY/CONCLUSIONS

˃ Use of switchgear specs will ensure all vendor products are tested to the

same requirements and Ship Programs will no longer need to conduct risk

reduction testing

˃ UL will ensure that Navy COTS circuit breaker spec products are requalified

at regular intervals and maintain a list of qualified products

˃ Current and and future programs should invoke new Low Voltage

and Medium Voltage specs for switchboards, circuit breakers, and

protective relays as applicable

˃ MIL-DTL-16036 will be requested to be revised as necessary based on lessons-

learned from development of MIL-DTL-XX653

Documents

Switchgear & Circuit Breaker Specification … & Circuit Breaker Specification Developments For ... Ship spec/purchase spec required Commercial-Off-The-Shelf ... for Electrical Systems